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Workshop Additive Manufacturing in Biomedical application: - State of the art at Sirris (Belgium) - Future and perspective in Bioprinting
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le centre collectif de l’industrie technologique belge
Additive Manufacturing for Biomedical applications
Grégory Nolens & Carsten Engel
Workshop, January 23th 2014
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 2
130 experts & high-tech infrastructure
Collective centre
of the technology industry
• Non profit organization
• Industry owned
4,700 industrial interventions
(advice, projects, services)
•within 1,700 different companies
•whose 75% are SME’s
•24M EUR turnover
Mission
“Increase the competitiveness of companies of
the Agoria sectors through technological
innovations”
3
Additive Manufacturing/3D Printing :
Basic Principles
Basic data :
Layer by layer manufacturing
3D CAD File 3D STL File Sliced File
Starting point:
3D CAD file
CENG
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014
3D Printing – Next
• Obama said (feb. 2013): "A once-shuttered warehouse is
now a state-of-the art lab where new workers are mastering
the 3-D printing that has the potential to revolutionize the
way we make almost everything“
“We can’t wait” initiative
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 4
Fashion effect – public machine
• Design, gadget,
• but also functional and caring
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 5
Industrial and technical products
• Prototyping
• No assembly
• Personalized
• Technical
• Porous
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 6
23/01/2014 7
Additive Manufacturing : Basic Principles
Advantages of using AM … try something new !
• Low-cost ability to easily try out ideas generates many
innovations
• AM has seen children returning to making things. From
digital into reality.
• Testing the market with an idea with small production
• Alows inventors to realize their inventions and test
their market
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be |
23/01/2014 8
Additive Manufacturing : challenges
Variety of materials still not vast enough
Lack of precision on some technologies
Machines still very pricy (industrial)
Need of certification and qualification of materials & process
Lack of surface quality and finishing
Not suited for big series (automobile)
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be |
9
Additive Manufacturing technologies @ Sirris
SIRRIS – European leader: Most complete machine park
• 15 engineers and technicians
• Two locations: Liège (10 p.) and Charleroi (5 p.)
Rapid Prototyping / Tooling / Manufacturing
• Stereolithography (normal & hi-res)
• Paste polymerisation for ceramics and metals (Optoform)
• 3D Printing of plaster and metal powder
• Laser sintering of polymeric powder (PA,…): P360 – P390
• Objet Connex 500: bi-material
• Laser sintering of metal powder (parts and mould inserts)
• Electron Beam Melting (Arcam A2)
• 3D Printing of wax (Thermojet)
• Vacuum Casting of Alu, Bronze, Zamak
• Laser Cladding (EasyClad)
• Selective Laser melting (MTT)
• Mcor - paper
• Bi-material FDM system
CENG
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014
23/01/2014 10
Next generation pre-operative manufactured implants:
• Custom implant manufacture :
• CT-Scan
• CAD File of the patient is produced
• Engineer + Surgeon 3D implant approved
• FEM analysis (when needed)
• Custom manufacturing (low cost)
• Surgery
• Follow up
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be |
CENG
[Sirris ADD]
[Sirris ADD]
[Sirris ADD]
The utility of Additive Manufacturing technologies
in the medical field
11
Medical Additive Manufacturing Software:
ADD capacities & competencies
CENG
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | info@sirris.be |
• Materialise: Mimics
• Materialise: 3matic
• Marcam: Autofab
• Able Software Corp: 3D Doctor
• Medicim: Maxilim
• ProEngineer
• New: Lenexa: Analyze
• New: Brisbane: Anatomics
• (…)
[Mimics & 3-matic - Materialise]
23/01/2014 12
Additive Manufacturing in the medical field
Leading applications:
• Custom implant manufacture (Scanning/Custom Prosthesis Design) • Pre-surgical planning • Physician to physician communication
• Powerful patient presentation tool
• Medical student/resident education
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be |
CENG
[Z. Corp Medical Modeling Solutions]
[Z. Corp Medical Modeling Solutions]
[Arcam & Objet technology]
[Sirris ADD]
23/01/2014 13
Leading applications:
• Pre-surgical planning:
• Implant pre-contouring • Screw trajectory • Screw selection/location • Instrument selection • Technique rehearsal
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be |
CENG
[Objet]
[Objet]
[Objet Connex Eden 500]
[Objet]
“No matter how good our 3-D graphics are, there is
nothing like a model in your hands . . .”
The utility of Rapid Prototyping / Manufacturing in
the medical field
23/01/2014 14
Medical Field: CASE STUDIES @ SIRRIS
Leading applications:
• Physician to physician communication
• Powerful patient presentation tool
• Medical student/resident education
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be |
CENG
[Sirris ADD] [Sirris ADD]
[Sirris ADD] [Sirris ADD] [Sirris ADD] [Sirris ADD]
23/01/2014 15
Medical Field: CASE STUDIES @ SIRRIS
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be |
CENG
Spinal & CMF case studies in ceramic
• Porous scaffolds for Spine surgery
• In vivo testing for bone integration
• Validation production by Sirris Tech transfer
• Field: Maxillofacial Surgery in France, production in Belgium
[Sirris ADD]
[Sirris ADD] [Sirris ADD]
16
Medical field: Industrial Case studies
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be |
CENG
Project: “In vitro testing models - arteries”
• Goals:
• To gain biomechanical know-how
• Virtual prototyping, device testing, virtual design iterations
• Diagnostic research
• Technologies involved: Connex Eden 500 bi-material 3D inkjet printing
23/01/2014
23/01/2014 17
Medical Field: CASE STUDIES @ SIRRIS
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be |
CENG
Surgical Cutting Templates
• UCL-St Luc (Belgium) • UCL spin-off: VISYOS • Polyamide cutting patient-custom cutting tools
• SLS technology + bio-coating
[VISYOS] [VISYOS]
23/01/2014 18
Medical Field: CASE STUDIES @ SIRRIS
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be |
CENG
Surgical Cutting Templates – reimbursement problem
Surgical guides not reimbursed, but facts are:
- 1 min. in surgical theatre (estimated): 60€
- Mean of orthopedic surgery duration: 5-12h (18k-44k€)
- Surgical guide can reduce: 20-70% of the duration (TBC)
- Surgical guide cost: 50-300€
- Economy: estimated 3-30k€/surgery
19
Medical Field: CASE STUDIES in the world
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be |
CENG
23/01/2014
[Dr J. Poukens – Uhasselt, Xilloc Medical (Maastricht)]
20
World’s first total mandible implant in Titanium
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be |
CENG
23/01/2014
[UHasselt, Layerwise, Xilloc, Sirris, CamBioceramics, Orbis Medisch Centrum, Xios, KUL]
21 © sirris 2012 Charleroi | www.sirris.be | info@sirris.be |
CENG
Finger implant (Dr. P. Ledoux, Prof. G. Guerlement UMONS)
23/01/2014
Towards newly designed implants
[Université de Mons, Faculté Polytechnique]
22 © sirris 2012 Charleroi | www.sirris.be | info@sirris.be |
CENG
23/01/2014
The future of bio-manufacturing…not so far away!
23
process of printing biologically relevant materials (such as cells,
tissues, and biodegradable biomaterials) that will accomplish
one or more biological functions
What’s Bioprinting
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014
+
cells
Bio-glue
3D machine
Tissues/organs Scaffolds
+ cells
23/01/2014 24 © sirris 2012 Charleroi | www.sirris.be | info@sirris.be |
Bioprinting – an emerging technology
Bioprinting place in emerging technologies, from the Hype Cycle for Emerging
Technologies 2013- Gartner
25
Market approach interest for companies?
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014
• Applications:
• Drug discovery & Assays
• Cell therapy + Tissue Engineering
• Bioprocess
• In vitro diagnostic & research
• Food
26
Drug Discovery and Assays
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014
• Facts: Drug Discovery and Assays
• 90-95% of drugs approved on animal (mouse, rabbit, etc.), was not
for human lot of money lost, ethic problem
• Animal use: 10-100 Mio in US/year
• European Comission banning: FULL on cosmetic (2013), next
pharma (?)
27
Drug Discovery and Assays
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014
• Applications:
• Drug screening w/o animal
& less deviations
Pharmaceutical area
Drug X
Disease tissue
Treated tissue
Organovo’s targeted market
28
Cell Therapy & Tissue engineering
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014
• Facts: Tissue engineering
• Alternative to donor waiting list
• Limited available « material » resource (skin, organs, cells, …)
29
Cell Therapy & Tissue engineering
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014
• Facts: Cell Therapy
Cell therapy industry market
(2008–2014).
Graph showing the estimated
CTI revenues from 2008–2014
30
Cell Therapy & Tissue engineering
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014
• Facts: Cell Therapy
High potential for
Small defect repair
31
Cell Therapy & Tissue engineering
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014
• Applications:
• Large defect repair
32
Drug Discovery and Assays
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014
• Applications:
• Biocompatibility assays w/o animals (ISO)
Artificial skin Irritation
33
Technological approach
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014
• Applications:
• In vitro diag and Research
• Biomarker
• Drug kinetic
• Pathogen reaction
34
Biotechnolgies & Bioprocess
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014
• Applications:
• Biomolecule production in 3D
• Machine producers
35
Food & Agriculture
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014
• Applications:
• New food process?
Focus on food player with Life
Science approach: biomaterial
( e.g. Tissue engineering)
Bioprinting
• Where beginning R&D?
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 36
Tissue engineering basics
• Lamarck (1744–1829): La fonction crée l’organe
(The function creates the organ).
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 37
Tissue engineering basics
• Lamarck (1744–1829): the function creates the organ.
daylife example: tissue reacts to device
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 38
« 2nd skin » development
Tissue engineering basics
• One scaffold can be enough
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 39
Tube with structure mimicking vascular matrix Rat implantation
Cell infiltration differentiation scaffold disapear tissue restorated
Tissue engineering basics
Scaffolds + stem cells + growth factors = work better
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 40
Artificial heart tissue (Taylor, Minnesota, 2009)
Artificial kidney tissue
Scaffolds come from animal washed for cells
3D Bioprinting solutions
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 41
Personalized
scaffolds
incubation with
stem cells
IPL, UGent, …
3D Bioprinting solutions
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 42
Nanostructure for
fluidic, cell interaction,
scaffold,…
2PP (two photon
polymerisation)
Very small devices
Nanoscribe
3D Bioprinting solutions
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 43
Industrial machines
Personalized
scaffolds
incubation with
stem cells
(and cell printing)
EnvisionTech, GESIM, Regenovo (China)…
3D Bioprinting solutions
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 44
Personalized
scaffolds +
stem cells
incubation
Bioprinting players in the world
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 45
• Keyplayers outside Europe
• Dr. Shinya Yamanaka (JPUS): stem cells
• Dr. Anthony Atala (US, Boston)
• Wake Forest University (US, North Carolina)
• ACES (Australia) biopen
• China
Bioprinting players in Europe – few
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 46
47
CENG
« Medical Additive Manufacturing & Rapid Prototyping »
« Sirris »
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014
48
Sirris Additive Manufacturing: Contact
© sirris 2012 Charleroi | www.sirris.be | info@sirris.be |
CENG
23/01/2014
Carsten ENGEL, Ir, MBA
Department of Additive Manufacturing
Mail: carsten.engel@sirris.be
Mobile: +32 498 91 94 50
Skype: Carsten-Engel
SIRRIS
Rue Auguste Piccard, 20
B-6041 GOSSELIES BELGIUM
http://www.sirris.be
Grégory NOLENS, PhD
Department of Additive Manufacturing
Mail: gregory.nolens@sirris.be
Mobile: +32 498 91 94 75
Skype: gnolens
SIRRIS
Rue Auguste Piccard, 20
B-6041 GOSSELIES BELGIUM
http://www.sirris.be
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